Axle counting adds fail-safe control to laser diagnostics
Train DetectionFrance

Axle counting adds fail-safe control to laser diagnostics

Country
France
Partner
MERMEC
Segment
Main & Regional Line
Application
Track Vacancy Detection
Products
FAdC®, RSR123
Year
2025
Download

When MERMEC set out to install a laser-based Wheel Profile Measurement System in close proximity to the Eurotunnel, they faced a critical challenge: how to avoid unintended laser exposure without compromising the system’s ability to inspect up to 200 trains per day. To meet these requirements, MERMEC partnered with Frauscher.

In 2025, MERMEC commissioned the installation of a high-speed, laser-based Wheel Profile Measurement System for trains entering the Eurotunnel, capable of scanning up to 150 axles per train across nearly 200 trains per day at speeds up to 100 km/h. The constrained track layout left no room for protective barriers, creating a critical safety risk of unintended laser exposure to passengers and nearby trains.

To address this challenge, MERMEC partnered with Frauscher, utilising their Frauscher Advanced Counter FAdC® and Wheel Sensors RSR123. Frauscher developed a fully integrated, fail-safe solution that directly interfaces with MERMEC’s laser system. The system dynamically activates and deactivates laser emissions in real time based on train presence, monitored through two critical track sections. Relay outputs are configured to default to a safe state in the event of power loss or faults, ensuring maximum protection.

Delivered as a pre-configured, tested cubical, the solution simplified deployment and minimised on-site installation effort. Frauscher provided full support during commissioning and handover, enabling seamless integration. By combining precise axle counting with automated laser control, the project achieved a fully safety-certified, future-ready setup that eliminates manual intervention and mitigates the risk of accidental exposure, ensuring reliable, high-speed wheel inspections in a busy mainline environment.

Partnering with Frauscher on the prestigious Eurotunnel project highlights the power of combining complementary strengths. By bringing our advanced expertise and innovation capabilities together with Frauscher’s renowned know-how, we created a synergy that enabled us to tackle complex challenges and deliver exceptional results.
Enrico Betterle

MERMEC

Dual-track monitoring

The FAdC® monitors both adjacent track sections in parallel, enabling precise control of laser triggering based on real-time train detection.

Fail-safe safety logic

Relay outputs are designed to default to a safe state during outages, preventing unintended laser operation.

Turnkey system integration

Solution was delivered in a pre-configured cubical, being fully tested and ready for deployment, with installation support included.

Dynamic control for live environments

The intelligent interface ensures that laser systems only activate when safe to do so which is crucial in busy mainline applications.

Future-ready platform

The flexible internal logic of the FAdC® allows the system to be customised according to operator´s needs, offering a flexible and reliable solution.

Similar Projects
This might also interest you
1/5
Train Detection, ServicesUnited Kingdom of Great Britain and Northern Ireland

Cutting delays through data-driven maintenance

Frauscher has supported the Paddington project with the adoption of Frauscher Insights Diagnostics, a cloud-based monitoring solution that increases data usefulness and availability. By providing faster fault analysis and health messages, Frauscher Insights has helped Network Rail improve reliability, reduce downtime and delay minutes by up to 80%, and shift towards a proactive maintenance approach.
Learn More
Train DetectionIndia

Ensuring reliable rail operations across India´s longest rail-road bridge

The Bogibeel Bridge is India’s longest rail-road bridge that connects Assam and Arunachal Pradesh, carrying both rail and road traffic across the Brahmaputra River. Harsh environmental conditions and structural constraints made conventional signalling unworkable. The Frauscher Advanced Counter FAdC® axle counting system was selected for its proven reliability and low maintenance under these challenging conditions.
Learn More
Data TransmissionIndia

South Central Railway

The Vijayawada Division of Indian Railways introduced a new train detection system with data transmission functionality to overcome the challenges of the existing BPAC and conventional quad cable-based systems. Frauscher implemented the Frauscher Advanced Counter FAdC®, featuring full redundancy, advanced reset mechanisms and remote diagnostics. This upgrade delivers significant cost savings and enhanced system availability for the operator.
Learn More
ServicesAustria

Salzburger Lokalbahn

Frauscher supported the Salzburger Lokalbahn, a regional railway in Austria, with a service assignment that included both the maintenance of Frauscher wheel sensors and axle counters as well as hands-on training for the installation personnel. The customer benefited from efficient troubleshooting and tailored training delivered directly on their own equipment.
Learn More
Train DetectionUnited Kingdom of Great Britain and Northern Ireland

The Borders Railway Project

From Shawfair to Tweedbank, the Borders Railway rail route underwent significant renovations after 45 years of disconnect due to Beeching cuts. Our Frauscher UK & Ireland team were involved in providing innovative solutions for train detection for a section of the Borders Railway route.
Learn More